Ceramic matrix composite component and a method of attaching a static seal to a ceramic matrix composite component

ABSTRACT

A ceramic matrix composite (CMC) component and a method of attaching a static seal to a ceramic matrix composite component are provided. The CMC component includes a first end and a second end. A CMC metal interface member is attached to the second end. The CMC metal interface member is operable to join to a static seal in a gas turbine.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/666,815 filed on Jun. 30, 2012 and entitled “CERAMIC MATRIX COMPOSITE COMPONENT AND A METHOD OF ATTACHING A STATIC SEAL TO A CERAMIC MATRIX COMPOSITE COMPONENT,” the disclosure of which is incorporated by reference as if fully rewritten herein.

FIELD OF THE INVENTION

The present invention relates generally to turbines. More specifically, to a ceramic matrix composite (CMC) component and a method of attaching a metal seal to the ceramic matrix composite component.

BACKGROUND OF THE INVENTION

A number of techniques have been used in the past to manufacture turbine engine components, such as turbine blades or nozzles using ceramic matrix composites (CMC). One method of manufacturing CMC components relates to the production of silicon carbide matrix composites containing fibrous material that is infiltrated with molten silicon, herein referred to as the Silcomp process. The fibers generally have diameters of about 140 micrometers or greater, which prevents intricate, complex shapes, such as turbine blade components, to be manufactured by the Silcomp process.

Another technique of manufacturing CMC turbine blades is the method known as the slurry cast melt infiltration (MI) process. In one method of manufacturing using the slurry cast MI method, CMCs are produced by initially providing plies of balanced two-dimensional (2D) woven cloth comprising silicon carbide (SiC)-containing fibers, having two weave directions at substantially 90° angles to each other, with substantially the same number of fibers running in both directions of the weave.

Generally, such turbine components require attachment to adjoining metallic hardware and/or metallic surfaces. Two disadvantages associated with attaching a CMC to metallic hardware are the wear of the metallic hardware by the hard, abrasive ceramic material surface, and the lack of load distribution in the CMC. Load distribution is critical in the interfaces between the CMC components and metal surfaces, such as shrouds. Typically, metallic shims or ceramic cloths have been interposed between the CMC and metallic surfaces to improve load distribution. Wear is typically reduced by the application of coatings to the metallic hardware or coatings to the nozzle attachment surfaces.

Therefore, a ceramic matrix composite (CMC) component and a method of attaching a metal seal to a CMC component that do not suffer from the above drawbacks is desirable in the art.

SUMMARY OF THE INVENTION

According to an exemplary embodiment of the present disclosure, a ceramic matrix composite component is provided. The ceramic matrix composite component includes a first end and a second end. The ceramic matrix composite component includes a CMC metal interface member attached to the second end. The CMC metal interface member is operable to join to a static seal in a gas turbine.

According to another exemplary embodiment of the present disclosure, a method of attaching a static seal to a ceramic matrix composite component is provided. The method includes providing a ceramic matrix composite component having a first end and a second end. The method includes providing a CMC metal interface member. The method includes attaching the CMC metal interface member to the second end of the ceramic matrix composite component. The method includes providing a static seal and joining the static seal to the CMC metal interface member. The CMC metal interface member forms a plenum for purging rotor air.

Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective schematic section view of a CMC component of the present disclosure.

FIG. 2 is a perspective schematic section view of a CMC component of the present disclosure.

FIG. 3 is a schematic top partial view of a CMC component of the present disclosure.

FIG. 4 is a flow chart of the method of attaching a static seal to a CMC component of the present disclosure.

Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts.

DETAILED DESCRIPTION OF THE INVENTION

Provided is a ceramic matrix composite (CMC) component and a method of attaching a metal seal to the CMC component.

One aspect of an embodiment of the present disclosure includes providing a honeycomb seal attachment for a CMC component. Another aspect of the present disclosure is that the system allows for different thermal growth of the CMC component and the CMC metal interface member. Yet another aspect of the present disclosure is that the system provides airfoil cavity sealing. Another aspect of the present disclosure is that the system provides a plenum to feed rotor purge air.

FIGS. 1 and 2 are perspective schematic section views of a CMC component 10. CMC component may include a first end 14 and a second end 16 opposite the first end. CMC component 10 may include an impingement baffle cavity surrounded by outer layers 12. CMC component 10 may be a non-rotating component, such as, but not limited to, vanes or nozzles. For example, as depicted in the figures CMC component 10 may be a nozzle. In one embodiment, CMC component 10 may be attached to a nozzle hanger 80. Nozzle hanger 80 may be attached by any suitable means to a case 90 of a gas turbine. CMC component 10 may be adjacent to rotating blades 100 in gas turbine.

According to one embodiment, CMC component may include a CMC metal interface member attached to second end of CMC component creating a plenum underneath CMC component to distribute air when needed for rotor purge. For example, as shown in FIGS. 1 and 2, CMC component 10 may include a CMC metal interface member 50 or seal box attached to second end 16 of CMC component 10. CMC metal interface member 50 may create a plenum underneath CMC component 10 to distribute air when needed for rotor purge. As shown in FIG. 2, the air used to purge the rotor is the arrow labeled 120. In one embodiment, as shown, CMC metal interface member 50 may span a single CMC component 10. In an alternative embodiment, CMC metal interface member 50 may span a number of CMC components 10 and may span up to a full 360 degree ring around CMC component 10. Material for CMC metal interface member 50 may include, but is not limited to, metals, metal alloys, and combinations thereof, for example the alloys may include nickel-based superalloys, cobalt-based superalloys, and combinations thereof. CMC metal interface 50 may include a feed tube 64 that exits into a channel 54 adjacent to static seal 40. For example, as shown in FIGS. 1 and 2, feed tube 60 may protrude from CMC metal interface 50 into impingement baffle cavity 30. In an alternative embodiment, feed tube 64 may extend down from impingement baffle cavity 30 into CMC metal interface 50. In another embodiment, instead of using feed tube 64, to create plenum, attachment member 70 may include a channel or aperture (not shown) to receive rotor purge air 120. In an alternative embodiment, CMC metal interface 50 may be unpressurized.

According to one embodiment, CMC metal interface member may include an attachment member. For example, as shown in FIGS. 1 and 2, CMC metal interface member 50 includes an attachment member 70. Attachment member 70 may be attached to CMC metal interface member 50 by any suitable means, such as, but not limited to, tapping attachment member 70 into CMC metal interface member 50, using a nut to secure attachment member 70 to CMC metal interface member 50, using an insert to secure attachment member 70 to CMC metal interface member 50. Material for attachment member 70 may include, but is not limited to, metals, metal alloys, and combinations thereof, for example the alloys may include nickel-based superalloys, cobalt-based superalloys, and combinations thereof.

According to one embodiment, CMC metal interface member may attach to CMC component by attachment member. For example, as shown in FIGS. 1 and 2, CMC metal interface member 50 may attach to CMC component 10 by attachment member 70. As shown in FIG. 3, attachment member 70 may attach to impingement baffle cavity 30 of CMC component 10. In one embodiment, attachment member 70 may be a bolt of any desired length. In one embodiment, impingement baffle cavity 30 may include an aperture (not shown) for receiving attachment member, where the aperture may be threaded to receive attachment member 70. In another embodiment, attachment member 70 may not be secured in impingement baffle cavity 30, instead a nut or other stopping member may be used to hold attachment member 70 securely in place at second end 16 of CMC component 10.

According to one embodiment, CMC metal interface member may provide a surface to join static seal to CMC component. For example, as shown in FIGS. 1 and 2, CMC metal interface member 50 may provide a surface to join a static seal 40 to CMC component 10. Static seal 40 may be attached to CMC metal interface member 50 by any suitable joining means, such as, but not limited to, brazing and welding. Joint 46 between CMC metal interface 50 and static seal 40 is shown in FIGS. 1 and 2. In one embodiment, static seal 40 may be a honeycomb seal. Material for static seal 40 may be selected from, but not limited to, metals, metal alloys, and combinations thereof, for example, the alloys may include nickel-based superalloys, cobalt-based superalloys, and combinations thereof. Static seal 40 may be adjacent rotating seals 110 in gas turbine.

According to one embodiment, a method of attaching a metal seal to a ceramic matrix component may include using a CMC interface member and a static seal. For example, FIG. 4 depicts a flow chart of a method 400 of attaching metal seal 40 to ceramic matrix composite component 10. Method 400 may include providing ceramic matrix composite component 10 having first end 14 and second end 16, step 401 (see FIGS. 1 and 2). Method 400 may include providing CMC metal interface member 50, step 403 (see FIGS. 1 and 2). Method 400 may include attaching CMC metal interface member 50 to second end 16 of ceramic matrix composite component 10, step 405 (see FIGS. 1 and 2). Method 400 may include providing static seal 40, step 407 (see FIGS. 1 and 2). Method 400 may include joining static seal 40 to CMC metal interface member 50, step 409 (see FIGS. 1 and 2). CMC metal interface member 50 may form a plenum for purging rotor air and may provide a surface to attach static seal 40, which may be metal, to CMC component 10.

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. 

What is claimed is:
 1. A ceramic matrix composite component comprising: a first end; a second end; and a CMC metal interface member attached to the second end; wherein the CMC metal interface member is operable to join to a static seal in a gas turbine.
 2. The ceramic matrix composite of claim 1, wherein the ceramic matrix composite component is a static component.
 3. The ceramic matrix composite of claim 1, wherein the ceramic matrix composite component is a vane or a nozzle.
 4. The ceramic matrix composite of claim 1, wherein the static seal is a honeycomb seal.
 5. The ceramic matrix composite of claim 1, wherein the static seal is attached to the CMC metal interface member by brazing or welding.
 6. The ceramic matrix composite of claim 1, wherein the CMC metal interface member is attached to the second end by a bolt.
 7. A method of attaching a metal seal to a ceramic matrix composite component comprising: providing a ceramic matrix composite component having a first end and a second end; providing a CMC metal interface member; attaching the CMC metal interface member to the second end of the ceramic matrix composite component; providing a static seal; and joining the static seal to the CMC metal interface member; wherein the CMC metal interface member forms a plenum for purging rotor air.
 8. The method of claim 7, wherein the ceramic matrix composite component is a static component.
 9. The method of claim 7, wherein the ceramic matrix composite component is a vane or a nozzle.
 10. The method of claim 7, wherein the static seal is a honeycomb seal.
 11. The method of claim 7, wherein the static seal is joined to the CMC metal interface member by brazing or welding.
 12. The method of claim 7, wherein the CMC metal interface member is attached to the second end of the ceramic matrix component by a bolt. 